Northern Lights M1064D User manual

OPERATOR’S
MANUAL
OM2-2
For Models:
M1064A, M1064D, M1064T1, M1064T2,
M1066A1, M1066A2, M1066A3, M1066T,
M40C2, M55C2, M65C2, & M99C2

Diesel engine exhaust and some of its constitu-
ents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
— CALIFORNIA —
Proposition 65 Warning:
Northern Lights
4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]
Copyright ©2013 Northern Lights, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern Lights, Inc.
Printed in U.S.A.
PART NO.: OM2-2 1/17

OM2-2 1/17
1
Read this operator's manual thoroughly before starting to operate your equipment.
This manual contains information you will need to run and service your new unit.
OPERATOR'S MANUAL
#OM2-2 for Models:
M1064A, M1064D, M1064T1, M1064T2, M1066A1, M1066A2,
M1066A3, M1066T, M40C2, M55C2, M65C2, and M99C2
INTRODUCTION ..................................................2
Models Included .................................................2
Model Numbers ..................................................2
Serial Numbers ...................................................2
WARRANTY ...........................................................3
SAFETY RULES..............................................3 - 7
Lockout / Tag Out Procedures ...................... 8
COMPONENT LOCATIONS
M1064.............................................................. 10
M1066...............................................................11
M40C2 ............................................................. 12
ENGINE & GENERATOR CONTROL PANELS
Series 3B & 4B ........................................ 13 - 14
Emission-Related Installation Instructions. 15
OPERATING PROCEDURES
Before Starting................................................. 15
Shutdown Procedures ...................................... 15
Break-In Period................................................ 16
SERVICING SCHEDULE CHARTS ...... 17 - 18
SERVICING
Lubrication - General....................................... 19
Checking Oil.................................................... 19
Oil Changes ..................................................... 19
Changing Oil Filter .......................................... 19
Air Filter .......................................................... 19
Valve Clearances.............................................. 20
Fuels - General................................................. 21
Crankshaft Vibration Damper (6 Cyl.) ............ 22
Fuel Filters .................................................22- 23
Bleeding the Fuel System ................................ 23
Injector Service........................................ 23 - 25
Injection Pump......................................... 25 - 27
Turbocharger.................................................... 28
Turbo Boost ..................................................... 28
Cooling System - General................................ 28
Engine Coolant Specications................. 28 - 29
Cooling System Flushing................................. 30
Heat Exchanger Cleaning ................................ 30
Zinc Electrodes ........................................ 30 - 31
Raw Water Pump ............................................. 31
Generator Ends ................................................ 31
Electrical System - General ............................. 31
Booster Batteries.............................................. 32
Battery Care ..................................................... 32
Winterizing / Out-of-Service ........................... 32
TROUBLESHOOTING
Electrical .......................................................... 32
Engine ...................................................... 33 - 34
WIRING DIAGRAMS
AC Wiring................................................ 35 - 37
DC Wiring................................................ 38 - 48
Panel Wiring....................................... 49 - 51
ON-BOARD SPARE PARTS ........................... 52
Proprietary Information
This publication is the property of Northern Lights, Inc.
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All rights reserved. Litho U.S.A. Publication number OM2-2 1/17
Table of Contents

OM2-2 1/17
2
Servicing of marine engines and generator sets
presents unique problems. In many cases boats cannot
be moved to a repair facility. Marine engines cannot
be compared to the servicing of automobiles, trucks or
even farm equipment. Failures often occur in remote
areas far from competent assistance. Marine engines
are taxed far more severely than auto or truck engines;
therefore, maintenance schedules must be adhered to
more strictly.
Failures begin with minor problems that are overlooked
and become amplied when not corrected during
routine maintenance.
As operator, it is your obligation to learn about your
equipment and its proper maintenance. This is not a
comprehensive technical service manual. Nor will it
make the reader into an expert mechanic. Its aim is to
aid you in maintaining your unit properly.
Introduction
A, D, & T
M - Northern Lights marine generator set
Model number
106 mm bore, 4 Cylinder
or
106 mm bore, 6 Cylinder
Model numbers give the unit's application, block model, aspiration, and RPM:
A - Aftercooled
D - Naturally aspirated
T - Turbocharged
++
Northern Lights®aftercooled, 1800 RPM
marine diesel generator set with a John Deere
Powertech Tier II 4045 engine block with an
electronically controlled fuel system.
Northern Lights®naturally aspirated, 1800
RPM marine diesel generator set with a John
Deere Powertech Tier II 4045 engine block
with a mechanically controlled fuel system.
M1064D
M1064 or 1066
=
=
MP55C2 =
Northern Lights®turbocharged marine
generator set with a John Deere Powertech
Tier II 4045 engine block with a mechanically
controlled fuel system.
Northern Lights®turbocharged marine
generator set with a John Deere Powertech
Tier II 4045 engine block with an electronically
controlled fuel system.
Northern Lights®aftercooled marine generator
set with a John Deere Powertech Tier II 6068
series 1 engine block with an electronically
controlled fuel system.
Northern Lights®turbocharged marine
generator set with a John Deere Powertech
Tier II 6068 engine block with an electronically
controlled fuel system.
40 kW Northern Lights®commercial marine
generator set with a John Deere Powertech
Tier II 4045 engine block with a mechanically
controlled fuel system.
55 kW Northern Lights®commercial marine
generator set with a John Deere Powertech
Tier II 4045 engine block and a mechanically
controlled fuel system.
65 kW Northern Lights®commercial marine
generator set with a John Deere Powertech
Tier II 6068 engine block and an electronically
controlled fuel system.
99 kW Northern Lights®commercial marine
generator with a John Deere Powertech Tier
II 6068 engine block and an electronically
controlled fuel system.
M1064T1 =
==
MP65C2
MP99C2
When referencing Northern Lights equipment by serial number, please refer only to the number
stamped on the Northern Lights®serial number plate.
M1064T2
=
=
MP40C2
=
M1066A1
M1064A =
M1066T
Serial Numberss
Model Numberss

OM2-2 1/17
3
A warranty registration certicate is supplied
with your set. The extent of coverage is described
in the Limited Warranty Statement. We recommend
that you study the statement carefully.
NOTE: If the warranty is to apply, the servicing
instructions outlined in this manual must be
followed. If further information is needed, please
contact an authorized dealer or the factory.
Warranty
Revised 4-10-12
Safety Rules
NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents.
You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
IMPORTANT SAFETY INSTRUCTIONS.
Electromagnetic equipment, including generator sets
and their accessories, can cause bodily harm and
life threatening injuries when improperly installed,
operated or maintained. To prevent accidents be aware
of potential dangers and act safely.
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL,
PRIOR TO THE INSTALLATION
OF ANY GENERATOR SET OR
ACCESSORY. KEEP THESE
INSTRUCTIONS FOR FUTURE
REFERENCE.
Recognize Safety Symbols and Instructions
In addition to the information found in this section, this
operator’s manual uses three dierent signal words to
outline potential dangers of a specic nature.
Follow All Safety Instructions
Carefully read and understand
all safety messages in this
manual and on your machine’s
safety signs. Keep signs in good
and clean condition. Replace
missing or damaged signs. Be
sure new equipment components and repair parts
include the current safety signs. For replacement signs,
proper placement of safety signs or clarication on any
safety issue, consult your Northern Lights dealer or the
factory.
There can be additional safety information contained
on parts and components from outside suppliers
that is not reproduced in this manual. Consult the
suppliers for additional safety information.
Learn how to operate the machine and how to use
the controls properly. Only trained personnel should
operate machines, or work on or around them.
Keep you machine in proper working condition.
UNAUTHORIZED MODIFICATIONS TO THE
MACHINERY MAY IMPAIR ITS FUNCTION
AND SAFETY PARAMETERS.
Prevent Bypass and Accidental Starting
!
WARNING
Do not start engine by shorting
across start terminal. Engine will
start if normal circuitry is bypassed,
creating a hazard by runaway
machinery.
Start engine only from operator’s station.
Handle Fuel Safely - Avoid Flames
!
WARNING
Diesel is highly ammable and should be treated
with care at all times. Do do not refuel while
smoking or when near sparks or open ame.
ALWAYS STOP ENGINE
BEFORE FUELING
MACHINE. Always ll
portable fuel tank outdoors.
Never fuel a hot engine.
!
DANGER
!
WARNING
!
CAUTION
DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.